A Motorized System for Loading and Unloading Press Dies in Plate Heat Exchanger Manufacturing and Its Comprehensive Analysis

The production of corrugated plates relies on hydraulic press machines, their capacities adjusted according to plate dimensions. However, the process involves time-consuming changes of heavy Press Dies, which can impede overall plant efficiency. To tackle this issue, a suggested remedy focuses on partially automating the process of loading and unloading Press dies. This mechanical setup comprises a table fitted with rollers and linear motion guideways. It is propelled by a ball screw mechanism powered by a servo motor and managed by a worm and worm gearbox. A chassis was meticulously designed to enhance the plant's efficiency, considering material selection and conducting detailed calculations. A comprehensive Design Failure Modes and Effects Analysis (DFMEA) was carried out, determining the calculated Risk Priority Number (RPN) for the system. In essence, the proposed solution seeks to improve efficiency and safety in plate heat exchanger manufacturing by reducing the press machine's idle time during die change operations to one hour or less. The system can efficiently load dies in the 2-to-16-ton range, covering a 2.5-m stroke distance with minimal human intervention. The seamlessly integrated system holds the potential to streamline the manufacturing process and optimize overall plant productivity.